FACULTY OF CHEMICAL & PROCESS ENGINEERING TECHNOLOGY

BKF 3923 PROCESS SYNTHESIS

PRESENTER : GOI YI KEN (KA17024)

NGU KEE SOON(KA17073)

NUR ATIQAHFARANI BINTI MOHAMED AZAMAN (KA17269)

NURHAMIZAH ADLIN BINTI ABDUL HALIM (KA17295)

GROUP : Production of n-Butanol

LECTURER : DR. MOHD SABRI BIN MAHMUD

TECHNICAL CONTENT 1
INTRODUCTION
 Guerbet Process Hydroformylation Fermentation
Reactants Ethanol and Water Propylene and syngas (mixture of CO and H2) Carbohydrate feed (cellulose and glucose) and water

Reaction type Reversible Irreversible Irreversible

Reactions At first, ethanol is dehydrogenated to
acetaldehyde, which then undergoes aldol
condensation with another molecule of
acetaldehyde to form crotonaldehyde. Finally, the
crotonaldehyde is doubly hydrogenated to form n-
butanol.
At first stage, propylene gas and syn gas are A mixture of acetone, butanol and ethanol in water,
pressurized and bubbled through liquid phase of also known as ABE is produced by metabolism
catalyst to form butanal by hydroformylation. pathway of bacteria Clostridium Acetobutylicum.
Then, butanal along with unreacted H2 and CO
enter the second reactor to be hydrogenated into
butanol.

Products n-butanol, C6 alcohol, crotyl alcohol, water, n-butanol, n-butanal, i-butanal, propane Acetone, n-butanol, ethanol
ethylene, acetaldehyde, crotonaldehyde and n-
butanal
Catalyst Hydroxyapatite (HAP) First reactor: Biological enzymes
Rh/TPP liquid catalyst
Second reactor:
Supported nickel catalyst
Yield 81.2% 90-95% 60-65%
Conversion Conversion of ethanol is 7.6% First reactor: Conversion by mass of feedstock is 20% for wheat
Conversion of propylene can reach over 85% straw as feedstock
Second reactor:
Convert butanal into butanol, with 95-98%
conversion
Temperature 603K First reactor: 363-383K Room Temperature
Second reactor: 413K
Feed Material 95%EtOH, 5%H2O 1 kmol of propylene: 3.33 kmol of syngas. Wheat straw, water
Syngas:
60% H2, 30% CO, 5% CH4, 5% CO2
Pressure 5.7 bar First reactor: 7-10 bar Atmospheric pressure
Second reactor: 4.5 bar
Safety and health risk Low Low Low
Profit margin 0.591 1.21 0.636
LEVEL 1 – MODE OF OPERATION
Process Requirements Operation Mode
Capacity 10 000 MT/yr of n-butanol Since capacity more than 5000 MT/yr, continuous reactor is
used

Raw materials delivery Deliver to plant using tanker trucks Batch mode

Products delivery Deliver to port using tanker trucks Batch mode

Products quality non FDA Can be batch or continuous

Operational flexibility 1 product only Can be batch or continuous

Feedstock availability consistent supply Continuous mode

Rate of reaction Relatively fast Continuous mode

Equipment fouling low Continuous mode

Safety low risk Continuous mode

After considered process requirements showed as above, a semibatch process with

continuous reactor and separation system as well as batch mode raw materials and
products delivery is decided.
LEVEL 2- INPUT AND OUTPUT STRUCTURE
2.1 Feed and Products Destination
The feed materials are: The products are:
Materials Composition Price (USD/kmol)
Propylene Pure 41238.4 Price
Materials Composition
H2 & CO: Varied* (USD/kmol)
Syngas CH4: 5% as impurity 2721.6
CO2: 5% as impurity
n-Butanol 99.5% 111180
Hydrogen Pure 900

2.2 Feed impurities

• Methane and carbon dioxide exist as impurities in feed syngas.

• Because of the boiling point of methane and carbon dioxide is fairly close to boiling point of hydrogen
and carbon monoxide, it is difficult to separating them from feed stream.

• To separate them at the product stream along with by-product propane and unreacted syngas and
propylene from i-butanal and n-butanal which have large boiling point different.
2.3 Output Destination
2.4 Input-Output Block Flow Diagram (BFD)
Output Components Destination
Propylene (FPC3H6)
n-Butanal Intermediate product, Carbon monoxide (FPCO)
Hydrogen (FPH2)
enter reactor 2 Syngas (FF1CO, FF1H2, Carbon dioxide (FPCO2)
FF1CH4, FF1CO2) Propane (FPC3H8)
i-Butanal Valuable by-product
Methane (FPCH4)

Propylene Separated as gaseous

Propylene (FF1C3H6)
stream and burnt as fuel Process n-Butanol (FPnBut)
Reactor 1

Carbon
monoxide i-Butanal (FPiBA)
Hydrogen (FF2H2)
Hydrogen

Carbon dioxide 2.5 Degree of Freedom

Propane Unknown Variables 14
Independent -4
Methane reaction
Stoichiometric -5
n-Butanol Main product balance
Composition of -2
Reactor 2

n-Butanal Recycle to extinction impurities

Degree of Freedom 3 (conversion 1, conversion 2,
Hydrogen Recycle to extinction feed ratio)
2.6 Material Balance
• Our production target is 10 000 MT/yr of n-butanol. Thus, continuous reactor design is suitable for our
production.
• This process consists 2 reactors, the first reactor convert syngas and propylene to n-butanal and the
second reactor convert n-butanal to n-butanol, which is our target product.
• To fulfil the materials balance, backward calculation method is used, thus materials balance of reactor
2 is solved first instead of reactor 1.
• Both reactors are assuming to be isothermal and no significant pressure drop.

Table 1: Summary on Materials Balance for Reactors

*yellow highlights represent desired product.

Component Flow Reactor 2 Reactor 1

Rate, mol/hr In Out In Out
n-Butanol 0 16865
n-Butanal 17752.2 887.61 0 16865
Hydrogen 17752.2 887.61 49650 26060
Propylene 24825 1241.3
Carbon Monoxide 24825 1271.5
i-Butanal 0 6688.6
Propane 0 30.3
Carbon Dioxide (inert) 4137.5 4137.5
Methane (inert) 4137.5 4137.5
2.7 Economic Potential at Level 2 (EP2)
EP2 = Revenue – Materials cost
Raw materials Product Price (USD/kmol) Flow Rate (mol/h)
Syngas 2721.6 82750
Propylene 41238.4 24825
Hydrogen 900 16865*
n-Butanol 111180 16865

111180 16865 − 2721.6 82750 − 41238.4 24825 − 900 16865

𝐸𝑃2 =
16865(1000)
= 36.234 USD/kmol n-Butanol
*noted that the flow rate of hydrogen used in this calculation is consider 100% conversion of
hydrogen in reactor 2. This is because all unreacted hydrogen going out of reactor 2 will be
recycled to extinction.
LEVEL 3 - REACTOR AND RECYCLE SCHEME
3.1 Discussion on Reactor Systems

The production of n-butanol from propylene and syngas requires 2 reactor system.
• Reactor system 1 involve hydroformylation of propylene to form n-butanal,
• reactor system 2 further process n-butanal to n-butanol by catalytic hydrogenation.

Main Reaction in Reactor System 1: Propylene (C3H6) + H2 + CO → n-Butanal (nBA)

Main Reaction in Reactor System 2: n-Butanal (nBA) + H2 → n-butanol (nBut)

• Operate in isothermal condition and no pressure drop.

Reactor System 1 Reactor System 2

Type of reactor CSTR 1 CSTR 2 PBR

Catalyst Rh/TPP liquid Rh/TPP liquid silica supported

catalyst catalyst nickel catalyst

Size 75.090 Lcat 94.254 Lcat 1024.73 kg cat

Temperature 383 K 383 K 573 K

Pressure 10 bar 10 bar 10 bar

Conversion 0.8 from 0.8 to 0.95 0.95

Selectivity 2.51 No side reaction

3.2 Recycle streams

• Because of equimolar feed and same stoichiometric coefficient of reaction, the amount of n-butanal and
hydrogen at the outlet of reactor 2 is equal.
• They are recycled into reactor 2 until extinction without purging.

Table show destination of outlet stream

Outlet Components Destination
n-Butanal Intermediate product, enter reactor 2
i-Butanal Valuable by-product
Propylene Separated as gaseous stream and burnt
Reactor 1

Carbon monoxide as fuel

Hydrogen
Carbon dioxide
Propane
Methane
n-Butanol Main product
Reactor

n-Butanal Recycle to extinction

Hydrogen Recycle to extinction
2
3.3 Block Flow Diagram (BFD)
 3.4 Heat Effect of Reactor System 1
Assuming 𝐹𝐶3𝐻6.0 =20000 mol/h, 𝐹𝐶𝑂.0 =20000 mol/h and 𝐹𝐻2.0 = 40000 mol/h, v

Figure 1: Levenspiel Plot Figure 2: X vs T Plot

From the shape of Levenspiel plot, the most suitable reactor
configuration is a CSTR with conversion at the minimum point From the X vs T plot, we found that the reaction is
of the curve, which is X=0.56, follow by a PBR to X=0.95. exothermic as T increase along with X.
However, due to Rh/TPP liquid catalyst is used, PBR is not
suitable. Instead, 2 CSTRs in series is consider in reactor system
design.
 3.4 Heat Effect of Reactor System 2
Using equimolar feed of hydrogen and n-butanal at 17000 mol/h,

Figure 3: Levenspiel Plot Figure 2: X vs T Plot

The size of adiabatic PBR required for this reaction can be
determined from the area under the Levenspiel plot multiply by
feed flow rate of n-butanal, which is 17752.15 mol/h. The size
of PBR at 95% converson is W=255.703 kgcat. By comparing
to 1024.73 kgcat of isothermal PBR, the size of adiabatic
reactor is much smaller.
From the X vs T plot, we found that the reaction is
exothermic as T increase along with X. At our
targeted conversion (X=0.95) the temperature is
900.13 K.
3.6 Economic Potential Level 3
𝑜
The purchase cost 𝐶𝑃 is calculated using the formula below (Turton R., Bailie R.C, Whiting
W.B., Analysis, Synthesis and Design of Chemical Process):
𝑜 2
𝑙𝑜𝑔10 𝐶𝑃 = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 𝐴 + 𝐾3 𝑙𝑜𝑔10 𝐴
K1 K2 K3 A
Centrifugal 2.2897 1.3604 -0.1027 450 kW
CSTR 1 4.7116 -0.5521 0.0004 75.090 m3
CSTR 2 4.7116 -0.5521 0.0004 94.254 m3
PBR 3.5565 0.3776 0.0905 0.256 m3
*from (Turton R., Bailie R.C, Whiting W.B., Analysis, Synthesis and Design of Chemical
Process)
Total cost of equipment = 161301.014
Catalyst Price
Rh/TPP 24.50 /kg
Nickel catalyst 30 /kg
* from Alibaba.com
Total cost of catalysts = 11828.93
Total cost of equipment and catalyst = 173129.944
Expected payback period = 3 years
Annualized cost = 57709.981
EP2 = 36233.93 /kmol n-Butanol
= 36.234 /kmol n-Butanol x 134916.32 kmol n-Butanol/year
= 4888557.94 USD/year

EP3 = EP2 – annualized equipment cost

= 4888557.94 – 57709.981
= 4830847.02 USD/year
= 35.80 USD/kmol n-Butanol
3.7 Conclusion
Design Reason/ Explaination
CSTR is used Catalyst in liquid form
CSTRs in series To reduce volume of reactor

Reactor System 1
Isothermal reactor design at 383K Exothermic reaction, T rise with X. High T
can cause significant amount of catalyst
solvent to evaporate.
CSTR 1 Size =75.09 Lcat, X =0.8
CSTR 2 Size =94.254 Lcat, X =0.95
Cooling system required To maintain the reactors in isothermal
condition.
PBR is used Solid catalyst and gaseous reactants

Reactor System 2
Adiabatic reactor design require less volume of reactor, no cooling
system required
Conversion of adiabatic PBR X = 0.95
Inlet temperature 573K
Outlet temperature 900.13K
Size of adiabatic PBR size = 255.703 kgcat
Separation System 1 No recycle stream
Recycle Stream

Separation System 2 Unreacted hydrogen and n-butanal are

recycled back into Reactor System 2
Heater Heater is required to preheat the recycle
stream before enter Reactor System 2
Compressor Compressors required to recycle gaseous
stream back to Reactor System 2
LEVEL 4 – SEPARATION TRAINS The specification of the distillation
column is provided in Table 1.
Specification Value

Light key recovery 99.5%

Heavy key recovery 0.5%
Condenser pressure (bar) 2
Reboiler pressure (bar) 2
Type of condenser Total
Number of stages 40

The specification of the distillation

column is provided in Table 2.
Specification Value
Light key recovery 0.99
Heavy key recovery 0.01
Condenser pressure (bar) 2
Reboiler pressure (bar) 2
Type of condenser Total
Number of stages 25
 4.4 Material Energy Balance

Table 4: Summary of material energy balance for production of butanol from propylene and hydrogen
Stream Stream
101 102 103 104 105 106 107 108 109 110 111 112
113 114 115 116 117 118 119 201 202 203 203
From M- H- H- H- D- D-
unit - - 101 102 R-103 104 F-105 F-105 106 107 107 - From unit M-108 C-109 H-110 R-111 H-112 F-113 F-113 D-201 D-201 203 203
M- M- H- H- BUR H- D- BUR M- M-
To unit 101 101 102 R-103 104 F-105 N 106 107 N 108 108 To unit C-109 H-110 R-111 H-112 F-113 203 D-201 203 Tank M-108 M-108
Tempera 363.1 355.5 370.8 Temperatu
ture K 298 298 298 383 383 283 283 283 5 4 4 298 re K 298 298 573 900 383 383 383 382.19 411.49 382.19 382.19
Pressure bar 1 1 10 10 5 5 5 5 2 2 2 1
Pressure bar 1 10 10 5 5 5 5 2 2 2 2
Propylen mol 2534 2534 2534 1267. 1267. 893.0 374.3 374.3 374.3
mol/
e /hr 5.6 0 5.6 5.6 33 33 22 11 11 11 0 0
Propylene hr 0 0 0 0 0 0 0 0 0 0 0
Hydroge mol 5069 5069 5069 2660 2660 2660 6.105 6.105 6.105 1686
mol/ 17752. 17752. 17752.
n /hr 0 1.3 1.3 1.3 6.5 6.5 0.4 94 94 94 0 4.6
Hydrogen hr 2 2 2 887.61 887.61 882.5552 5.054835 5.054835 0 887.61 887.61
Carbon
mol 2534 2534 2534 1298. 1298. 1292. 5.376 5.376 5.376 Carbon mol/
monoxid
0 0 0 monoxide hr 0 0 0 0 0 0 0 0 0 0 0
e /hr 5.6 5.6 5.6 17 17 79 68 68 68
mol 4224. 4224. 4224. 4224. 4224. 4178. 45.74 45.74 45.74 mol/
Methane /hr 0 27 27 27 27 27 53 48 48 48 0 0 Methane hr 0 0 0 0 0 0 0 0 0 0 0
Carbon mol 4224. 4224. 4224. 4224. 4224. 3934. 289.4 289.4 290.4 Carbon mol/
dioxide /hr 0 27 27 27 27 27 83 45 45 66 0 0 dioxide hr 0 0 0 0 0 0 0 0 0 0 0
n- mol 1721 1721 382.6 1683 1683 84.18 1675 mol/ 17752. 17752. 17752.
butanal /hr 0 0 0 0 8.7 8.7 23 6.1 6.1 04 1.9 0 n-butanal hr 2 2 2 887.61 887.61 156.2863 852.5381 844.0127 8.620437 1000.3 1000.3
mol 6828. 6828. 205.1 6623. 6623. 6590. 84.18 mol/
i-butanal /hr 0 0 0 0 88 88 74 7 7 58 04 0 i-butanal hr 0 0 0 0 0 0 0 0 0 0 0
n- mol mol/
butanol /hr 0 0 0 0 0 0 0 0 0 0 0 0 n-butanol hr 0 0 0 16865 16865 35.07188 16708.71 167.0871 16597.82 0 0
mol 30.93 30.93 20.35 10.57 10.57 10.57 mol/
Propane /hr 0 0 0 0 55 55 83 71 71 71 0 0 Propane hr 0 0 0 0 0 0 0 0 0 0 0
Total mol 2534 8448 1098 1098 6169 6169 3750 2419 2419 7407. 1683 1686 mol/ 35504. 35504. 35504. 18640. 18640. 1073.913 17566.302 1016.1546 16606.440 1887.9 1887.9
flow /hr 5.6 5.5 31 31 9.1 9.1 7.8 1.3 1.3 35 6.1 4.6 Total flow hr 4 4 4 2 2 4 9 4 4 1 1
4.5 Summary of heat duty for separation process

Unit Heat duty (kJ/hr)

H-104 -117463
F-105 0
H-106 477135
D-107
-Reboiler heating required 4697090
-Condenser cooling required 4655000
H-112 -2564130
F-113 0
D-201
-Reboiler heating required 363380
-Condenser cooling required 164169
 4.6 Sizing of Separation Process
For the flash drum 1 and flash drum 2 is assumed as vertical drum.
• First by calculating the permissible vapor velocity, u perm, The sizing of distillation column is first assumed as tray tower
uperm = Kdrum pL-pvpv
Kdrum is an empirical constant (ft/s) and typically ranges from 0.1 to 0.35. then using the formula: H = n(HETP)
Kdrum = exp (A + B ln (Flv) + C (ln(Flv))2 + D (ln(Flv))3 + E (ln(Flv))4)
Where:
Flv = WLWvpvpL 𝑇
• Cross-sectional area,
where: HETP = 𝐸𝑜 ,Eo = 0.492 (uL a)^-0.245
Ac = VMWvuperm(3600)pv
Where MW v is average vapor molecular weight
Set the length/diameter ratio by following rule of thumb which is for
vertical flash drum of DISTILLATION 1 DISTILLATION 2
htotal / D ranges from 3.0 to 5.0 because this range can minimize the total
vessel weight. HEIGHT(m) 48.2 33.25
A -1.877478097 DIAMETER(m) 4.52 1.65
B -0.8145804597
VOLUME(m) 218.04 71.097
C -0.1870744085
D -0.0145228667
E -0.0010148518

FLASH 1 FLASH 2
DIAMETER (m) 0.401 0.127
HEIGHT (m) 2 0.6357
4.7 Economic Potential Level 4
The purchase cost 𝐶𝑃𝑜 is calculated using the formula below (Turton R., Bailie R.C, Whiting
W.B., Analysis, Synthesis and Design of Chemical Process):
𝑙𝑜𝑔10 𝐶𝑃𝑜 = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 𝐴 + 𝐾3 𝑙𝑜𝑔10 𝐴 2

K1 K2 K3 A
Flash drum 1 3.4974 0.4485 0.1074 0.264 m3
(horizontal)
Flash drum 2 3.4974 0.4485 0.1074 0.0084 m3
(horizontal)
Distillation 3.4974 0.4485 0.1074 218.04 m3
column 1
(Packed)
Distillation 3.4974 0.4485 0.1074 71.10 m3
column 2
(Packed)
*from (Turton R., Bailie R.C, Whiting W.B., Analysis, Synthesis and Design of Chemical
Process)
Total cost of equipment = 2113940.91

Expected payback period = 3 years

Annualized cost = 704646.97
EP4 = EP3 – annualized equipment cost
= 4830847.02 – 704646.97
= 4126200.05 USD/year
= 30.583 USD/kmol of n-butanol
LEVEL 5 – HEAT INTEGRATION
950

850

750
Temperature, K

650

550

450

350

250
0 500000 1000000 1500000 2000000 2500000 3000000
Cumulative Enthalpy, kJ/h

Cold Hot

From the diagram, we can observe that both plots In the figure above, the shaded area represents heat energy
intercept at 298 K. By assuming that minimum that can be utilized by installing heat exchangers with 10 K
temperature difference of heat exchangers is 10 K, minimum temperature difference. For the lines that lie
another graph is plotted. outside the shaded area, heat or cold utilities are required
to reach desired temperature.
 -

Based on the figure above, 2 heat exchangers

Based on the figure above, 7 heat exchangers are required.
are required. Besides, 210589.69 kJ/hr of
Besides, 1415236.7 kJ/hr of heat is required to supply by hot
heat is required to absorb by cold utility.
utility.
Mumne Network
 PC
Cooling

LEVEL 6-
101
water inlet
Condenser

Cooling
water outlet PROCESS
Reflux
Drum LT
102
LC
102
CONTROL AND
PT
INSTRUMENTAT
ION
101 201

119
Unit distillation column D-102 is choosen to study its P&ID.

LT
101

D-201 TT TC
101 101

Hot steam
inltet
Hot steam
Reboiler outlet

LC AT AA
101 101 101

202
Level Control System 101 Pressure Control System 101
Controlled Variable Liquid level at bottom of distillation column Controlled Variable Pressure at the top of distillation column
Manipulated Variable Flowrate of bottom stream 202 Manipulated Variable Flowrate of cooling water inlet into the condenser
Disturbance Flowrate of feed stream 119 Disturbance Temperature of cooling water, temperature in the column
Description When the liquid level at the bottom of the column is higher Description When then pressure at the top of the column rise higher than
than set point, valve at stream 202 will open more to increase set point, the control system will increase opening of valve at
flowrate to drain the column, causing liquid level drop to set cooling water inlet. This will increase flowrate of cooling water
point. Vice versa. into the condenser, more vapour will be condensed and
pressure will drop to set point again. Vice versa.
Temperature Control System 101
Controlled Variable Temperature at the bottom of distillation column Level Control System 102
Manipulated Variable Flowrate of hot stream into the reboiler Controlled Variable Liquid level in the reflux drum
Disturbance Flowrate of feed stream 119, temperature and pressure of hot Manipulated Variable Flowrate of distillate stream 201
steam inlet. Disturbance Temperature of cooling water, Reflux ratio
Description When the temperature at the bottom of the column drop Description When the liquid level reflux drum is higher than set point, valve
beyond set point, the control system will increase opening of at stream 201 will open more to increase flowrate to drain the
valve at hot steam inlet to increase flowrate of hot steam. The reflux drum and the liquid level will return to set point. Vice
temperature of vapour return to the column will increase, versa.
causing the temperature at the bottom of column rise to set
point. Vice versa.
 HAZOP CHECKLIST
Study Tittle Distillation process
Part Consider Distillation Column,Pressure Controller, Condenser, Reboiler,Valve, Pipe Date 18/12/2019
Activity Distillate the n-butanol from n-butanal
Material N-butanal, N-butanol

Process
Parameter Deviation What if Causes Consequences Action
What if low flow at 1. Partially block of pipe 1. Low flow of products obtained. The 1. Install low flow alarm at outlet of
outlet stream. 201 and 202. process may upset. Column will distillation column. Interlock flow will shut
overheated or overpressure due to down the inlet flow. Consequence of
accumulate of products at the pipe. maintenance is progress. Install backup
pipe line.
What if low flow at 2. Valve malfunction. 2. Condensation process slow down. Less 2. Install low flow indicator. Manual or
Flow Low
cooling water inlet Leakage of cooling water product is condensed to liquid form. The backup valve is install. Relief valve is
inlet pipe. pressure of the column increase. Process install to prevent high pressure Action of
may upset. cleaning process is done if any pipe
leakage. Check and adjust manually the
level controller-201 to prevent low level
in reflux drum.
What if low flow at hot 3. Valve malfunction. 3. Reboiler cannot preheated the outlet 3. Install low flow alarm at the hot steam
steam inlet. Leakage or partially block product. The process may upset. Leakage inlet. Install backup valve if valve
of hot steam inlet. of hot material may cause fire or malfunction. If pipe block or leak, first,
explosion. check the temperature controller to
manual partially or totally close the valve.
Interlock flow will shut down the inlet
flowrate for further cleaning process.
What if overflow of 1. Valve malfunction or 1. More products is condensed as liquid 2. Install high flow indicator. Manual or
Flow High cooling water inlet bypass valve is open. form. Pressure drop across the column. backup valve is install. Check and adjust
The process upset. manually the pressure controller-101 to
prevent low pressure in the column.
What if overflow of 2. Loss of still reboiler 2. Unbalance flow of the bottom products 2. Install high flow alarm. Manual adjust
reboiler outlet control. Valve at stream and recycle to column. Process upset. the level control if the reboiler loss
202 malfunction. control. Install backup or manual valve if
valve at stream 202 malfunction. Place
the reboiler at checklist and regular
 HAZOP CHECKLIST
Study Tittle Distillation process
Part Consider Distillation Column,Pressure Controller, Condenser, Reboiler,Valve, Pipe Date 18/12/2019
Activity Distillate the n-butanol from n-butanal
Material N-butanal, N-butanol
Process Parameter Deviation What if Causes Consequences Action
What if low temperature 1. Hot stream inlet valve 1. Temperature for the reboiler 1. Install low temperature alarm at
in reboiler. malfunction. product is lower. separation process distillation column. Manual valve is
upset occur. set for the hot stream inlet.
What if low temperature 2. Valve at cooling water 2. More distillate products is 2. Install low temperature alarm at
for the condenser inlet malfunction. condensed, pressure drop across the condenser. Install backup valve.
distillation column.
Temperature Low What if low temperature 2. Reflux drum or condenser 2. The separation process is upset. 2. Install low temperature indicator
in distillation column malfunction. The pipe More products are accumulated in for column. Temperature interlock
leakage or partially block. the column, may cause overpressure shut down the inlet flow rate. Check
or overheated. whether reflux drum or condenser
malfunction. Maintenance action
taken.

What if high 1. Totally blockage of 1. Product will accumulate at the 1. Check the valve 202 immediately.
temperature in reboiler. product pipe. reboiler and may cause system If failure, then open backup valve. If
collapse not, detect the pipe which is
blockage then temperature interlock
shut down the still hot stream inlet.
Install high temperature alarm for
further prevention.

Temperature High 2. Loss of still reboiler 2. Overheating of the bottom 2. Install high temperature alarm.
control products. Process upset. Temperature interlock shut down the
reboiler to prevent high temperature
of column.

What if high 3. Pipe is partially blockage 3. Less gases are condensed into 3. Install relief valve. Install high
temperature in for cooling water inlet. liquid. High pressure generate in temperature alarm for the
condenser. distillation column. Process is upset. condenser. Maintenance action
taken.